SIL in the practice: Safety by design

23/04/2015

Products Solutions Services

Safety by Design

Mechanical integrity ………. safety in the design phase ………. safety in the manufacturing phase ………. safety in the field operation phase

Leading Technologies and Services

for a Safe Plant Operation

Slide 1 Alain ENGELS

23/04/2015

Safety BY DESIGN – A life time commitment

• Endress+Hauser design standards

• Material selection

• Design simulations using “Finite Element Methods”

• Mechanical design stress testing

• Welding Procedure Specifications

• Sealing concepts

• Inherently safer designs

Mechanical integrity ……….safety in the design phase


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Endress+Hauser design standards

Slide 3

• Design and testing experience

built on generations of product

history within Endress+Hauser ,

Endress+Hauser customers and

industry/academic organizations

• Costly and unproductive

complexity is avoided by

standardized development across

all Endress+Hauser operations

• These standards help

Endress+Hauser reduce risk in the

design, manufacturing and

documentation of products, in turn

helping us reducing risks to our

customers

Alain ENGELS

23/04/2015

Material selection

Metals • The selection of the correct type and form of metals used within

an instrument is built on years of experience and testing.

Plastics/elastomers • A wide variety of non metallic polymer materials are available

for seals, containment, insulation, etc

Glass/ceramics • Non-metallic materials such as glasses, graphite, ceramics are

typically selected for seals, insulation, etc. for demanding

service especially under higher temperatures and pressures

Heterogeneous assemblies • Assemblies with combinations of materials can have complex

interactions that must be suitable for the design service.

• Understanding how the combination of forms and compositions

will behave are critical to achieving a low risk service design.

Slide 4

Advanced ceramics & graphite in high temperature process seals

Alain ENGELS

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Design Simulations

Endress+Hauser uses the latest design FEA tools to

simulate real world effects (i.e. fatigue, failure) on

designs from mechanical forces, heat, vibration, fluid

flow and other physical stresses to reduce risk.

stre

ss

strain

elastic area

yield strength


Finite Element Methods

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Stress testing

Vibration testing • Testing of prototype components or final products to ensure the final

design will provide expected resistance

• Amplitude and frequencies (g forces) are varied in X, Y and Z directions

Shock testing • Subjecting components or final products to abrupt forces or strikes to

test integrity as specified

Fatigue testing • Some components in a design subjected to mechanical movement over

time may develop weaknesses leading to failure

• Repetitive flexing or mechanical movement may be conducted over a

period of time to ensure the right material for the design is used

Burst testing • Testing is conducted on a component or final product to pinpoint the

level at which function or containment is lost


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Welding procedure specifications

Welding Procedure Specifications (WPQR & WPS) are managed

according to required standards

Clear and transparent guidelines prevent defective work in

manufacturing and customer documentation.


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Sealing concepts Instruments by their nature are often installed in

hazardous areas, inserted into extreme process pressures,

temperatures and exposed to all types of materials

An instrument needs to be robust enough to avoid a

release of process material or needs to be predictable in

how it releases process material so risk is managed

Showing a customer the complexity in a cross section

picture or model of some of our instruments may help

them grasp there is more mechanical design built in than

what appears from the outside

Slide 8

Advanced ceramics – graphite process seals for high pressure and extreme temperatures

Advanced metallic spring loaded PTFE sealing concept.

Alain ENGELS

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Inherently “Safer” designs

Non intrusive measurement technologies • No mechanical impairment of the process equipment by using non-

intrusive / non-invasive instrument designs • Radiometric level and density measurements

• Ultrasonic Clamp on flow measurement

• Skin point temperature measurements

Mechanical assemblies with predictable failure modes

Rupture

Disk holder

Predetermined breaking point

Slide 9

Annunciation

Opening behind

second line of

defense

Alain ENGELS

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Safety BY DESIGN – A life time commitment

• Manufacturing quality assurance

• Material traceability

• Positive Material Identification (PMI)

testing

• Radiographic (RT) testing

• Dye penetrant (DPI) testing

• Welding Procedure Qualification Reports

• Hydrostatic pressure testing

• Helium leakage testing

Mechanical integrity ... Safety in the manufacturing phase


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Manufacturing quality assurance

• The quality assurance systems at Endress+Hauser are based on ISO

defined criteria and are regularly audited by outside agencies.

• ISO 9001 Quality Management System

• ISO 14001 Environmental Management System

• OHSAS 18001 Occupational Health and Safety Management System

• Each employee in our organization shares the responsibility for

consistently producing the products expected by our customers

• Dedication to quality and continuous quality improvement is cultural

at Endress+Hauser….and our safety message as well!

Reference resources slide for more information and access


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Material traceability

• Maintaining absolute material identification, inventory and

traceability from incoming stock to finished delivered product and

documentation is a core strength of Endress+Hauser manufacturing.

• Material traceability and sometimes proof of traceability is required

by process plant engineering and construction operations to ensure

predictable containment integrity


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Positive Material Identification (PMI)

• Endress+Hauser uses PMI testing as a non-destructive method which does not

affect the material properties. It is not a substitute for a traceability certificate

• PMI testing is performed by emitting X-rays on the material to be tested, which

then responds by sending out XRF (X-ray fluorescence) signals of varying energy

and intensity depending on its chemical composition. The XRF signals are then

recorded by an XRF analyze

• Studies show that in Petrochemical and Refinery facilities almost half of the

largest losses are a direct result of failures in piping systems. PMI testing is

commonly used method to eliminate any material mixing errors


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Radiographic (RT) testing

• Endress+Hauser uses industrial radiography or

X-ray testing to inspect materials for hidden flaws

to reduce risk

• Reveals material defects (visible as well as hidden)

on metallic materials .

• Especially well suited for welding seam analysis

since even very small defects can be identified.

• Non-destructive as it does not affect the material

properties or leave any marks on the measured

surface.

• Report generated by qualified Endress+Hauser

personnel is included with the instrument

documentation when specified


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Dye penetration (DPI) testing

• Dye Penetrant Inspection (DPI), also called Liquid Penetrant

Inspection (LPI) or Penetrant Testing (PT), is used by

Endress+Hauser to locate surface-breaking defects in all non-porous

materials

• LPI is used to detect casting, forging and welding surface defects such

as hairline cracks, surface porosity, leaks in new products, and

fatigue cracks on components


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Welding procedure qualification

• Welding seams on many Endress+Hauser products are produced by automatic

welding machines according to instrument specific WPQR/WPS (Welding

Procedure Qualification Record/Welding Procedure Specification) and

supervised/controlled by approved welding engineers.

• Frequent inspection of both welding machines and the resulting welding seams are

conducted to maintain the highest quality demands and regulatory requirements.

• Customers can fully rely on the welding seam quality of any Endress+Hauser

welded device


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Hydrostatic pressure testing

• Hydrostatic testing is a safer way to verify the integrity of a

manufactured instrumentation component that is designed for

pressure service.

• Many Endress+Hauser components are 100% tested while others are

tested to meet specific customer or industry requirements


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Helium leakage testing

• Leak testing is part of the

Endress+Hauser non-

destructive test NDT portfolio

that can be applied to a

fabricated component to verify

it is leak proof

• For example, Liquiphant

extensions are 100% Helium

tested to ensure component

welding is fully accomplished

and there are no leak points


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Safety DURING OPERATIONS – A life time commitment

• Examples of Endress+Hauser

Mechanical Integrity in field

operations Mechanical integrity diagnostics

Inherently safer components

Process containment

Mechanical integrity ………. Safety in the field operation phase


23/04/2015

Examples of mechanical integrity in field operations

Levelflex level

Liquiphant Soliphant

levelswitch

Cerabar/ Deltabar pressure

Prowirl Vortex

flow

iTHERM® StrongSens

temperature Memosens Analytical

Promass Coriolis

Mass flow Engineered

Temperature


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Liquiphant - Engineering at a glance

Special Features: • operating temperatures -60 to

280 °C ( -75 to 535°F) (300°C (570°F) for max. 50 h cumulated)

• pressures up to 100 bar ( 1450 psi)

• highly corrosion resistant material Alloy C22 (2.4602)

• Including welded-in gas tight feed-through (second line of defense)

FTL7x

electronic- insert

Welded gas tight feed-through (second line of defense)

temperaturespacer part

Ex d - thread

Piezo-stack drive

vibrating fork

Alain ENGELS Slide 21

The gas tight feed-through prevents e.g. leakage of toxic media

Highest Safety Even in Case of Damaged Sensor

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Soliphant M – engineering at a glance

Improved housing

Smaller

More vibration resistant

through new clamping disk

New seal for F15

Dip switches for selection of:

Sensitivity Switching delay Min/Max function Diagnosis

Climate seal

NAMUR electronics

New threaded drive

Welding seam is eliminated

Smaller and stronger

316L sensor material

No material mix

Optional abrasive

resistant coatings

2 fork types

Short fork for small tanks

1¼“ NPT diaphragm

Save sensor circuit

SIL 2

Gas-tight feedthrough for

Ex d/de (FTM51, FTM52)

New fork geometry

Stronger root


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Cerabar S/Deltabar S - Secondary Containment

Ceramic Sensor

• gas tight containment to 120 bar (1740 psi)

• diagnostics in DP cell advising of membrane

rupture

Metal Sensor

• pressurized containment (gas tight

feed through, 400 bar (5800 psi) proven)

• completely welded membrane, no seals

Cerabar S

Deltabar S

Differential pressure Sensor

• containment to 1050 bar (15225 psi)

• function control

• withstands alternating loads


The gas-tight feed through prevents leakage of medium in case of failure

Highest safety by second process barrier

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Levelflex – FMP54 – Heavy duty under harsh conditions

FMP54

Special Features:

• Robust design and gas tight glass feed-through

• -196 to +450 °C (-320 to 840 °F)

• Pressures up to 400 bar (5800 psi)

• High diffusion resistance using ceramic coupling and graphite seal

• Resistant against Superheated steam (ceramic seal) – application in steam boilers acc. to EN12952/12953 (NM, HW, Range)

• Finite element simulations

graphite

2nd process containment (gas tight glass feed- through)

ceramic


The gas tight feed-through prevents e.g. leakage of toxic media

Highest Safety at High Pressure and High Temperature

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Proline Prowirl – The reliable multi talent body

Application example:

Loading of liquid nitrogen at

-196°C/-320°F

Special features: Extremely robust basic body

design

Temperatures -200 to 400°C (-325 to 750°F) (optional 450°C (840°F))

Pressure levels up to PN250/ ANSI 1500 lb

Material stainless steel (standard), Alloy C-22 (e.g. corrosive applications)

Proline Prowirl

Shrunk and welded-in bluff body ensures safety during steam

hammers

Alain ENGELS Slide 25 High reliability and high life time even under extreme process conditions

(pressure, temperature)

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Proline Prowirl – the reliable multi-talent sensor

Special Features:

• Robust and unique DCS-Sensor

technology

• No aging or wear

• Insensitive versus water hammers

• Highest vibration resistance

(1g at 10…500Hz)

• Insensitive versus temperature shocks

(150K/s)

• Second containment

• Flow rate up to 120m/s (393 fps)

• Proven in use – above 250.000

installed Sensors

DCS = Differential Capacitance Sensor

Gas tight Glass feed-through


Unique DSC-Sensor technology with second containment

High Reliability, Safety and Long Term Stability

containment

HP version up to 160Bar

23/04/2015

Promass E200/F200 – Two wire-Coriolis-mass meter

Special Features:

• robust housing offers maximum operation safety in harsh environment

• industrial standards and requirements consistently realized

Promass E 200 – Standard device lay length according to NE132 (NAMUR)

Promass F 200 – the market leader in two wire technology


Increases safety and reduces costs for planning, procurement and operation

max. safety with standardized two wire concept

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Memosens is safe in all aspects

Memosens simplifies the operation

• Simply connect the sensors and they deliver reliable values immediately.

• Calibrate the sensors in the lab and exchange them on site in no time.

Memosens increases plant safety

• The inductive plug-in head eliminates all problems due to moisture.

• Digital transmission displays errors actively and enables you to react immediately.

• Simply exchanging the sensors in the field increases availability of measuring point.

Forms the basis for the first certified SIL 2 analytical measurement platform

Highest measuring safety and minimized risk for maintenance staff

inductive signal transfer

inductive energy supply

pH/ORP Oxygen Conductivity Chlorine


23/04/2015

Retractable holder–safe port to process for liquid analysis

Cleanfit CPA450 with service friendly safety

locking device:

• holds max pressure up to 12 bar ( 170 psi)

• avoids opening the retractable under

process pressure

Enhanced safety in the insertion position

• lock ring and

• safety locking device made from 316L

Cleanfit CPA472D with safe blocking system:

• No pneumatic positioning in process if a

sensor is not installed


23/04/2015

iTHERM® StrongSens

Robust thermometer with thin film sensor Special features:

• Robust Pt100 metering sensor with high vibration resistance for temperatures up to 500°C (60g)

• Robust verified and “calculated” design


Unique sensor technology for demanding applications

Longest life time with optimized operation safety

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Thermowell Calculation

Verification of the mechanical strength of a

thermowell for the individual process

conditions.

Calculation according to DIN 43772 or

ASME/ANSI PTC 19.3

Is the thermowell able to withstand the process

conditions?

Static process pressure

Dynamic flow pressure

Flow induced vibrations

Strength of material at process temperature


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Temperature Engineered Solution

Diagnostic and containment chamber –

second sealing barrier

Individual

thermowells –

first sealing

barrier

Connections for diagnostic chamber monitoring

Multipoint with Dual-sealing barriers Special features:

• Highest plant safety due to dual sealing barriers

• Safe diagnostic chamber monitoring under pressure ensures continuous plant operation

• Replaceable sensing elements ensures continuous plant operation

• Advanced diagnostics capabilities


Dual seal and diagnostic functions ensure …

Safe plant operation in high risk environment

23/04/2015 Slide 33

Temperature Engineered Solution– Multipoint TM911

Unmatched safety concept with up to 3 barriers

Safe operation also in fault condition (leakage)

No unplanned shut downs!

Alain ENGELS

23/04/2015

Mechanical integrity planning

• Endress+Hauser provide tools to take risk out of specifying the right

mechanical components for specific service

• Endress+Hauser trained personnel and customers who have the

experience or Endress+Hauser training rely on these tools


Applicator &

Selection Guides

23/04/2015


Any Questions?


23/04/2015


Thank you very much for your attention


SIL in the practice: Safety by design

Engineering

Transcript of SIL in the practice: Safety by design